Glowworm COMPACT 80p User guide

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221679H.11.00
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
Instructions for Use
Installation and Servicing
To be left with the user
This is a Cat I2H Appliance
6936
Fanned Flue Combination Boiler
With Honeywell gas control
G.C. No. 47 047 04A
COMPACT 80p
❑
✔
❑
✔
❑
✔
All replacement parts
All labour charges
All call-out charges
Guarantee Registration
REGISTER YOUR GLOW-WORM APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Thank you for installing a new Glow-worm appliance in your home.
Glow-worm appliances' are manufactured to the very highest standard so we are pleased
to offer our customers' a Comprehensive First Year Guarantee.
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
The instructions consist of three parts, User, Installation and Servicing Instructions, which include the Guarantee Registration Card.
The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use)
Regulations, be handed to the user on completion of the installation.

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Testing and Certification
This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler,
without permission, in writing, from Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.4.
CE Mark
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning
gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment
designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic
compatibility.
Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL
These can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is
broken.
Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or
going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
Important Information
Introduction 3
Clock Settings 4
Lighting the Boiler 5
General Data 1 7
Boiler Location 2 9
Flue and Ventilation 3 10
Heating System 4 11
Domestic Hot Water System 5 12
Installation Preparation and
Gas/Water Connections 6 13
Flue Preparation 7 14
Mounting the Boiler and Flue Fitting 8 16
Electrical Connections 9 18
Commissioning 10 20
General Data 11 23
Servicing 12 23
Fault Finding 13 24
Replacement Parts 14 32
Spare Parts 15 43
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

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AUTO RUN
MT WThFSSu
P
DAY HR MIN
P
R
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Introduction
Please read these instructions and follow them carefully for the
safe and economical use of your Combination boiler.
This boiler must have been installed by a competent person in
accordance with the current rules in force in the countries of
destination at the time of installation.
Once the controls are set, the boiler is automatic in operation.
The Compact combination boiler is able to provide room heating
as part of a central heating system and domestic hot water
direct from the cold water supply, without the need for secondary
storage.
The boiler can be fitted with one of two makes of clock, which
look like this:-
IMPORTANT NOTICE:
This boiler is for use only on G20 gas.
Gas Leak or Fault
If a gas leak or fault exists or is suspected, turn the boiler off and
consult your local gas company or your local installation/
servicing company.
Domestic Hot Water Temperature
NOTE. The mains incoming water temperature in the winter is
lower than in the summer.
The water temperature is factory preset and can not be
adjusted.
To achieve the same outlet water temperature in the winter, it
will be necessary to reduce the water flow rate using the hot
water tap.
Boilers Installed in Compartments
If the boiler has been fitted into a compartment or cupboard, do
not obstruct the compartment air supply vents.
Do not use the compartment for storage.
Electrical Supply
WARNING. The boiler must be earthed.
The boiler must be connected to a 230V~50Hz permanent
supply.
Connection of the whole electrical system of the boiler and any
heating system controls to the electrical supply, must be through
one common isolator.
Isolation should preferably be by a double pole switched fused
spur box. The fused spur box should be readily accessible and
preferably adjacent to the appliance. It should be identified as
to its use.
Alternatively a fused 3A 3 pin plug and shuttered unswitched
socket may be used.
The colours of three core flexible cable are, blue - neutral, brown
- live, green and yellow - earth.
As the markings on your plug may not correspond with these
colours continue as follows:-
The wire coloured blue must be connected to the terminal
marked “N” or “Black”.
The wire coloured brown must be connected to the terminal
marked “L” or “Red”.
The wire coloured green and yellow must be connected to the
terminal marked “E” or “Green” or the earth symbol .
PVC flexible cable having a conductor size of 0.75mm2(24/
0.20mm) must be used within the boiler casing to connect to the
boiler.
Electrical Supply Failure
The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the electrical
supply is restored.
If the power is off, except for short controlled periods, turn off the
pilot.
Note. The boiler safety cut-off may have operated, please refer
to the following section to reset.
Reset any external controls, to resume normal operation of the
central heating.
The digital timer, has a lithium battery back up and will not need
resetting. Unless it is without power for a considerable period.
Boiler Safety Cut-off Device
The boiler is fitted with a safety cut-off device to prevent damage
through overheating.
Should the main burner and pilot go out, for no apparent
reason, during normal use, allow the boiler and system to
cool down (waiting at least a minimum of four minutes),
relight the boiler as described in "To light the boiler".
Iftheproblempersists, turnthe boileroff andconsult your
installation/ servicing company.
The Gas Safety (Installation & Use)
Regulations
In your interests and that of safety it is the law that ALL gas
appliances are installed by competant persons in accordance
with the current issue of the above regulations.
6937
Clock / Timers
Digital timer Electro / mechanical
clock / timer
Instructions for Use

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Setting Timed Programmes
With the clock set to the correct time, see SETTING THE
CLOCK paragraphs 1-4, and then continue as follows:
1. Set RUN switch to P , the display will indicate
the 1st (ON) preset programme and the symbol .
2. Set day of week to be programmed by pressing the
DAY button.
Note: The days can be selected individually or as
groups:
Mon-Fri., Mon-Sat., Mon-Sun., Sat/Sun.
An arrow will be displayed under the day
or days selected.
3. Set time of day by pressing the buttons HR and MIN.
4. Press button P to confirm programmes, the
display will indicate the 2nd (OFF) preset programme
and subsequently, 3rd, 4th, 5th, 6th, 7th, 8th.
5. Repeat procedures 2, 3 and 4 until desired
programmes are set.
Note. It is not a requirement to use the 8 on/off
programmes.
6. Set the RUN switch the central position, your
appliance will now operate at the programmed times.
General Notes.
With the AUTO switch in the I position the central
heating will operated constantly ON.
With the AUTO switch in the O position the central
heating will not operate.
Soft Override button indicated by the
symbol , this function will override the current
central heating programme for the next available.
ON time programmes are indicated by the symbol .
Setting the Clock - Diagram 2
1. With both AUTO and RUN switches set to the central
position, press R reset button, the display will flash.
2. Set RUN switch to .
3. Set day of week by pressing button DAY.
4. Set time of day by pressing buttons HR and MIN.
5. Set RUN switch to the central position, colon will flash, this
indicates the clock is set.
With the clock set, the factory preset programme shown below
will operate.
Setting Instructions for Electro/mechanical
Clock - if fitted
This clock has a twenty four hour dial, that is, 1pm is 13.
To set the time, turn the whole face clockwise until the pointer
is against the time of day.
To set any “Off”time, push the tappets outwards.
To set any “On”time, push the tappets inwards.
Time can be set either “On”or “Off”in fifteen minute segments.
Note. The clock supplied could be fitted with an override device,
see diagram 1, which switches the clock programme “On”or
“Off”permanently.
The switch will need to be repositioned to resume programmed
working.
Diagram 1
OVERRIDE
SWITCH
POINTER
TAPPETS
CLOCK FACE
CONSTANT OFF
PROGRAMMED
CONSTANT ON
0
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6938
Setting Instructions for the 7 Day Digital
Clock/Timer
This is a 24 hour clock/timer, that is 1pm is 13:00, and has 8
“ON”and 8 “OFF”daily switching actions.
It is fitted with a lithium battery back up which protects the
programme in the event of an electrical failure. The battery
should have a life of several years.
Instructions for Use
Diagram 2
6939
MON/FRI
ON - 06:30
OFF - 08:30
ON - 16:30
OFF - 22:30
SAT/SUN
ON - 07:00
OFF - 09:00
ON - 16:00
OFF - 23:00
AUTO RUN
MT WThFSSu
P
DAY HR MIN
P
R
I

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To Light the Boiler
1. Check that all four isolating valves are open, the levers in line
with the valve bodies, see diagram 3.
2. Open the controls cover door an familiarize yourself with the
controls, see diagram 4.
3. CAUTION. A sealed pressurised system must be filled and
pressurised by a competent person.
Only operate the boiler when you are sure that the system has
been filled and pressurised. Check this by looking at the
pressure gauge “A”, it should read 0.7bar minimum.
4. Open a hot water tap, check that water flows, then close it.
5. If you are in any doubt about the boiler being filled with water
contact your installation/servicing company or the local gas
company.
6. Fully press and hold down the control knob “C”. Press and
release the piezo button “D”until the pilot burner lights, view
through window in the front case. When the pilot burner is lit,
keep control knob “C”pushed in for a further 15 seconds then
release. The pilot should remain alight.
7. IF THE PILOT GOES OUT NOW, OR ON ANY OTHER
OCCASION, A SAFETY DEVICE PREVENTS IMMEDIATE
RELIGHTING. WAIT AT LEAST FOUR MINUTES BEFORE
ATTEMPTING TO RELIGHT.
8. If the pilot burner fails to remain alight, repeat instruction 11.
but now hold down the control knob “C”for a little longer after the
pilot has lit.
9. Check the pilot is alight and stable.
10. Switch ON the electrical supply to the boiler at the external
isolator.
11. Set the switch “K”to ON 1 situated on the control fascia.
12. Check the light “E”is illuminated on the control fascia.
13. Set the summer / winter button “J”, light “H”or “F”will
illuminate.
Instructions for Use
14. Set “B”, clock/timer (if fitted) and any remote controls as
required.
For central heating operation set button “J”to “On”. The main
burner will ignite. Light “F”will illuminate.
Close the controls cover door.
To Turn the Boiler Off
For short periods only set switch “K”to 0. Turn off pilot light.
To turn the boiler off, turn the control knob “C”in the direction
of the arrow clockwise.
To turn on again following the "To light the boiler" instructions.
Water Temperatures
NOTE. The mains incoming water temperature in the winter is
lower than in the summer.
To achieve the same outlet water temperature in the winter, it
will be necessary to reduce the water flow rate using the hot
water tap.
Summer / Winter Selector Button
For central heating set button “J”to Winter light “F”will illuminate
as shown in diagram 4. The main burner will light.
When the heating is controlled by a room thermostat and/or a
time switch, button “J”must be set to Winter light “F”will
illuminate.
If a hot water tap is opened while the boiler is on for heating,
priority will be given to hot water.
Maintenance and Servicing
To ensure the continued efficient and safe operation of the
appliance it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.
To obtain service, please call your installer or Heatcall (Glow-
worm’s own service organisation) using the telephone number
behind the controls cover door.
Please be advised that the ‘Benchmark’logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on :- 01256 372300.
Clearances
The boiler requires a clearance in front, below and at the sides
of the casing for safety, servicing and maintenance access, see
diagram 2.1.
Protection Against Freezing
If the boiler is to be out of use for any long periods during severe
weather, it is recommended that the whole system, including
the combination boiler, should be drained to avoid the risk of
freezing.
If in doubt, contact you installation/servicing company for advice.
Diagram 3
GAS
SERVICE
COCK
HOT
WATER
OUT
COLD
WATER
SUPPLY IN
HEATING
FLOW
HEATING
RETURN
LEVER (OPEN)
COLD WATER
SUPPLY IN/OUT
SLOT (OPEN)
GAS SERVICE
COCK
LEVER (OPEN)
HEATING
FLOW/ RETURN
7310
SAFETY VALVE DISCHARGE
PIPE POSITION

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Instructions for Use
Draining and Filling
CAUTION. This boiler works in a pressurised system which
must only be drained, refilled and pressurised by a competent
person.
Note: If the pressure gauge indicates a loss of system pressure,
that is, less than 0.7bar, YOU MUST CONTACT YOUR
INSTALLER.
Pressure Relief Safety Valve
CAUTION. A pressure relief safety valve and discharge pipe is
fitted to the boiler. This valve must not be touched. Should there
be any discharge from the pipe, turn the boiler off, isolate from
the electrical supply and contact your installation/servicing
company. The outlet should be kept clear
Cleaning
WARNING. This appliance contains metal parts (components)
and care should be taken when handling and cleaning with
particular regard to edges.
The boiler casing can be cleaned using a mild liquid detergent
with a damp cloth, then a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as you may
damage the paint work
Boiler Casing
CAUTION. Do not remove or adjust the casing in any way, as
incorrect fitting may result in incorrect operation or failure to
operate at all. If in doubt seek advice from the local gas
company or your installation/servicing company.
Replacement Parts
If replacement parts are required apply to your local supplier or
British Gas.
Please quote the name of the appliance.
7565
7004
MAINS
ELECTRIC
SWITCH ‘K’
CONTROL
KNOB ‘C’
SUMMER/ WINTER
BUTTON ‘J’
PRESSURE
GAUGE ‘A’
Diagram 4
‘H’
‘G’
‘E’‘F’
PIEZO ‘D’
CONTROLS COVER
CONTROLS
FASCIA
CLOCK TIMER
IF FITTED ‘B’
KEY TO NEON LIGHTS
‘G’LOW WATER PRESSURE
‘H’SUMMER SETTING (HOT WATER OPERATION ONLY)
‘F’WINTER SETTING (HOT WATER AND CENTRAL HEATING OPERATION)
‘E’POWER ‘ON’

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C
L
H
9mm
JL
K K
22mm COMPRESSION
CENTRAL HEATING
15mm COMPRESSION
DOMESTIC WATER
Rc 1/2(1/2in. BSPT)
GAS CONNECTION
C
L
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E
NB
A
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FLUE
1 General Data
7029
1.1 Installation
Materials and equipment should be fit for their purpose and of
suitable quality and workmanship.
1.2 Important Notice
This boiler is for use only on natural gas, G20.
1.3 Sheet Metal Parts
WARNING. When installing or servicing this boiler care should
be taken when handling the edges of sheet metal parts to avoid
any possibility of personal injury.
1.4 Requirements
The installation of this boiler must be carried out by a competent
person in accordance with the current rules in force in the
countries of destination at the time of installation.
Manufacturer’s instructions, supplied.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
1.5 Data Label
The data label is on the inner case cover, see diagram 1.2.
1.6 Data
See table 1 and diagrams 1.1, 1.2 & 1.3.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
72.2%.
The value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
Lift Weight 33.4kg (73.63b)
Total Weight 42.8kg (94.36lb)
Gas connection Ø15mm compression
Heating and return Ø22mm compression
Domestic hot water Ø15mm compression
Safety valve Preset 3bar (43.5lbf/in2)
Safety valve discharge Ø15mm copper
Water content 1.66 litres (0.37 gallon)
■Expansion vessel capacity 6 litres (1.32 gallons)
Heating cold fill 0.7bar
pressure minimum (10.1lbf/in2)
❋D.H.W 0.8 to 10bar
working pressure
■Maximum Heating 60 litres
system water (13.2 gallons)
content using with a cold
fitted expansion fill pressure
vessel. of 0.7bar
Electrical supply 230V~50Hz
Electrical rating 154W fused 3A
Internal Fuse rating F1) Type T2A
F2) Type T315mA
■For larger systems use an additional expansion
vessel, see Section 4.
❋Boiler starts at an inlet pressure of 0.5bar but
requires 0.8bar for maximum output.
TABLE 1
ABCDEFGHJKLMN
450 700 300 100 75 128 225 18 135 65 110 80 144
Diagram 1.1

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1.7 Gas Supply
The gas installation shall be in accordance with the rules in force
in the countries of destination.
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.
1.8 Electrical Supply
WARNING. This boiler must be earthed.
All system components shall be of an approved type.
The electrical installation shall be in accordance with the current
rules in force in the countries of destination at the time of
installation.
Connection of the whole electrical system of the boiler and any
heating system controls to the electrical supply, must be through
one common isolator.
Isolation should be by a double pole switched fused spur box,
having a minimum contact separation of 3mm in each pole.
The fused spur box should be readily accessible and preferably
adjacent to the appliance.It should be identified as to its use.
Alternatively, a fused 3A 3pin plug and unswitched socket may
be used, provided they are not used in a room containing a bath
or shower.
The mains supply cable and other cables connected to the
boiler must be the PVC flexible type of at least 0.75mm2 (24/
0.20mm) .
1 General Data
HEPWORTHHEATINGLTD.,
BELPER,DERBYS.DE561JT
COMPACT 80P 457501
SERIAL
HEATING CIRCUIT PMS = 2.5 bar
DOMESTIC CIRCUIT PMW = 10 bar
SPECIFIC WATER RATE 11.22 l/min.
No.
GC No. 47-047-04A
0086
86/AU/582
GB IE
230V 50Hz 150W Fused at 3A
For use on : -G20 - 20 mbar
G20
This boiler is intended exclusively
to be installed on a gas supply
with a governed meter
~
MIN
DHW MAX. CH MAX.
HEAT INPUT NETT kW
kW
HEAT OUTPUT
10.720.09
17.6
25.5
HOT BURNER PRESSURE
mbar 1.2
7.6
13.0
23.45 8.79
INJECTOR:4.2mm 205766
I2H
TYPE :C - C
Q =
P =
NO Class5
x
3212
7507
Diagram 1.2
1.9 Heating System Controls
The heating system should have installed: a timer and room
thermostat controlling the boiler.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
Note: All systems must have at least one radiator not fitted with
a thermostatic valve.
Note: For further information, see The Building Regulations
1991 - Conservation of fuel and power, 1995 edition - Appendix
G, table 4b.
7643
Diagram 1.3
FANNED
FLUE AUTOMATIC
AIR VENT
PILOT
BURNER
EXPANSION
VESSEL
MAIN BURNER
HEAT EXCHANGER
PUMP
LOW WATER
PRESSURE
SWITCH
GAS VALVE
SAFETY
VALVE
SAFETY
VALVE
DISCHARGE
OVERHEAT
CUT-OFF
TEMP.
SENSOR
OVERHEAT
CUT-OFF
TEMP.
SENSOR
BYPASS
VALVE
D.H.W.
COLD
INLET
D.H.W.
HOT
OUTLET
C.H.
FLOW
C.H.
RETURN
FLOW
SENSOR
GAS

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25 ABOVE THE TOP OF
THE FLUE ELBOW
5
5
450
150
To achieve minimum "Installation" clearance of 5mm.
The side panels will have to be fitted prior
to boiler mounting.
6944
DIMENSIONS
IN MILLIMETRES Diagram 2.1
2.1 Location
This boiler must be installed in accordance with the rules in
force in the countries of destination.
This boiler is not suitable for outdoor installation.
Any electrical switch must be positioned so that it cannot be
touched by a person using the bath or shower.
The boiler must be mounted on a flat wall which is sufficiently
robust to take its weight, refer to Table 1, “Data”.
If the location of the boiler or any part of the system is subject
to severe cold weather conditions, it is recommended that a
frost thermostat is fitted. Any part of the system that may be
vulnerable to freezing must be protected.
2.2 Boilers in a Compartment
Where the installation of the boiler will be in an unusual position,
the current issue of BS6798 gives detailed guidance on these
requirements.
An existing cupboard or compartment modified for the purpose
may be used, providing minimum clearances are maintained.
Details of essential requirements for cupboard or compartment
design are given in the current issue of BS6798.
The doorway opening should be of sufficient size to allow for
easy removal of the boiler.
Where the boiler is fitted in a cupboard or compartment,
permanent ventillation is not required.
Any existing compartment air vents must not be removed or
blocked off.
2.3 Clearances
The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see diagram
2.1. Additional clearances may be required around the boiler for
installation.
2.4 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accorandce with the Institute of Gas Engineers
document IGE/UP/7/1998. If in doubt seek advice from the local
gas undertaking or Hepworth Heating Ltd.
2 Boiler Location

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A
A
F
GE
A
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
UNDER CAR PORT etc.
H,I
JD
F
K
MINIMUM
SPACING
2816
Diagram 3.1
3 Flue andVentilation
3.1 General
The flue must be installed in accordance with the rules in force
in the countries of destination.
3.2 Terminal Position
The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram 3.1.
The terminal must be exposed to the external air, the position
allowing free passage of air across it at all times.
Car port or similar extensions of a roof only, or roof and one wall,
require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required to
protect the roof if made of plastic sheeting. If the car port
comprises of a roof and two or more walls seek advice from the
local gas undertaking before installing the boiler.
If the terminal is fitted within 600mm below plastic guttering, an
aluminium shield 1500mm long should be fitted immediately
beneath the guttering or eaves. If the terminal is fitted within
450mm below painted eaves or a painted gutter, an aluminium
shield 750mm long should be fitted immediately beneath the
guttering or eaves.
3.3 Flue Options
There are various flue systems to choose from, as follows:
Standard Top Outlet Flue Pack - Pt.No. 230483
Extended Top Outlet Flue Pack - Pt. No. 230487
1 Metre Extension Kit - Pt. No. 230484
Optional Wall Liner Kit No. 900862
A Flue Bend Kit or Vertical Flue Kit can be supplied, see
Hepworth Heating "Flue Options Guide" for configurations
available.
45oFlue Bend Pack - Pt. No. 230485
90oFlue Bend Pack - Pt. No. 230486
In Line Flue Adapter Kit - Pt. No. 230488
Vertical Flue Kit No. 458115
3.4 Internal Access Flue
All flue assemblies are designed for internal installation, given
that there is sufficient clearances opposite to the flue for the
installation of the flue.
If there is insufficient clearance the flue can be installed from
outside.
For a wall thickness up to 300mm, provided that there is
sufficient space and the optional wall liner kit is used, the flue
can be installed from the inside.
For a wall thickness of over 300mm the external flue hole will
need to be made good from the outside, this also applies if you
use the flue kit without the optional wall liner kit, irrespective of
wall thickness.
3.5 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
a minimum of 50mm clearance from any part of the terminal and
be central over the terminal.
The guard should be similar to that shown in diagram 3.1 .
MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS
POSITION mm
A DIRECTLY BELOW AN OPENABLE
WINDOW, AIR VENT, OR ANY
OTHER VENTILATION OPENING 300
B BELOW GUTTER, DRAIN/SOIL PIPE 25
C BELOW EAVES 25
D BELOW A BALCONY 25
OR CAR PORT 200
E FROM VERTICAL DRAIN PIPES AND
SOIL PIPES 25
F FROM INTERNAL OR EXTERNAL
CORNERS 25
G ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
H FROM SURFACE FACING THE
TERMINAL 600
I FACING TERMINALS 1200
J FROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300
3.6 Room Ventilation
Ventilation must be provided in accordance with the rules in
force in the countries of destination. The boiler is room sealed,
so where the boiler is fitted in a room or space, a permanent air
vent is not required.
3.6 Cupboard/Compartment Ventilation
If the boiler is to be fitted in a cupboard or compartment. Refer
to Section 2.2.
TERMINAL GUARD TYPE K3
SUPPLIED BY :
Tower Flue Components Ltd.
Morley Road
Tonbridge
Kent
TN9 1RA

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11 221679H
0.00
1.00
2.00
3.00
4.00
5.00
0 5 10 15 20 25
Circuit flow rate (l/min)
Remaining conveying capacity (m H2O)
0
10
20
30
40
50
Dt (°C)
Dt at 60000 btu output
Dp (MH2O)
4.1 General Notes
The boiler is intended for use in a sealed system only.
4.2 Safety Valve
The safety valve is an integral part of the boiler.
It cannot be adjusted but has a manual test device.
4.3 Pressure Gauge
A pressure gauge is incorporated into the boiler to indicate the
system pressure.
The gauge has a cold fill set pointer.
4.4 Pump
The circulation pump is integral with the boiler.
The remaining circulating pressure head available from the
boiler is shown in diagram 4.1.
4.5 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of
6Litres, (1.32gall). If the system water content exceeds the
maximum quoted in Table 1, Data, an additional vessel should
be connected into the system as close as possible to the central
heating return connection of the boiler, see diagram 4.2.
The pressure shall not be less than the static head at the point
of connection, that is, the height of the top point of the system
above the expansion vessel.
4.6 Flow Rate
If required a valve can be incorporated in the main flow or return
of the system, valve “A”shown in the flow diagram 4.2. This
valve must be lockable and positioned so that inadvertent
closure or unauthorised interference is not possible.
Diagram 4.1
4 Heating System
4.7 Bypass
The bypass is an integral part of the boiler and cannot be
adjusted.
No external system bypass is required.
4.8 Filling Sealed Systems
Provision for filling the system at a low level must be made.
Three methods of filling are shown in diagram 4.3.
There must be no permanent connection to the mains water
supply, even through a non-return valve.
NOTE: It is important that fittings used for connection to potable
water comply with the water undertakers requirements.
4.9 Corrosion Inhibitor
If an inhibitor is to be used in the system, contact the inhibitor
manufacturer so that they can recommend their most suitable
product.
When fitting the boiler into an existing system, special care
should be taken to drain the entire system, including radiators,
then thoroughly cleaning out before fitting the boiler whether or
not adding an inhibitor.
4.10 Draining
A draining tap must be provided at the lowest points of the
system, which will allow the entire system to be drained. An
additional draining tap MUST be fitted close to the boiler.
The flow and return isolation valves are provided with drain
points for boiler heat exchanger drainage.
7487

Supplied By www.heating spares.co Tel. [phone]
12
221679H
BOILER
DOMESTIC
WATER
HOT
COLD SUPPLY
FILLING
POINT
DRAIN
POINT
’A’
FLOW
CONTROL
VALVE
HEATING
CIRCUIT
RETURN
ADDITIONAL
EXPANSION
VESSEL
(if required)
Diagram 4.3
METHOD 1
METHOD 2
METHOD 3
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS
SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
HEATING
SYSTEM
TEMPORARY
HOSE
HOSE
UNIONS
SERVICING
VALVE
SUPPLY
PIPE
SUPPLY STOP
VALVE
DOUBLE CHECK
VALVE ASSEMBLY
HEATING
SYSTEM
SERVICING
VALVE
SUPPLY
STOP VALVE
SUPPLY
PIPE
HOSE
UNIONS DOUBLE CHECK
VALVE ASSEMBLY
OVERFLOW
CISTERN
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
PRESSURE
REDUCING
VALVE
3132
4 Heating System
5.1 General
The domestic hot water service must be in accordance with the
rules in force in the countries of destination.
5.2 Water Pressure
For the minimum and maximum working pressures of the
domestic hot water circuit of the boiler refer to Diagram 1.2.
If the cold water supply pressure exceeds the maximum, a
governor must be fitted in the supply to the boiler to reduce the
pressure to within the limits given.
5 Domestic Hot Water System
7650
Diagram 4.2
5.3 “Hard”Water Areas
In areas where the water is “hard”, more than 200mg/litre, it is
recommended that a proprietary scale reducer is fitted in the
cold water supply to the boiler. Consult the local water company
for additional advice.
A double check valve assembly must be fitted upstream of the
scale reducer. For the relative position of the scale reducer and
pressure reducing valve, if required, refer to the manufacturer’s
instructions.

Supplied By www.heating spares.co Tel. [phone]
13 221679H
7028
UNION
CONNECTION
DISCHARGE
PIPE
SAFETY
VALVE
DISCHARGE
Diagram 6.2
SEALING
WASHER
REAR VIEW
OF BOILER
The installation requires the following components :-
1. Plumbing jig Carton
2. Boiler Carton
3. Flue Pack
6.1. Plumbing Jig
Remove from the carton the wall template, then follow the
instructions given on the template.
Note: It is important that the wall hanging bracket and the
service cock bracket are fitted to a flat and true wall area for
correct alignment with the boiler. Where this cannot be achieved
it is acceptable to pack out the service cock bracket to obtain the
correct alignment with the wall hanging bracket.
6.2 Gas Connection
Provision is made for the gas supply to be connected from
below the boiler, see diagrams 1.1 and 6.1 for position.
Refer also to “Gas Supply”, Section 1.7.
Make the gas supply connection to the gas service cock. While
making the connection, do not subject the gas service cock to
heat as you may damage the seals. Purge the gas supply.
6.3 Water Connections
Provision is made for the domestic cold water inlet to be
connected from below or through an internal wall at the rear of
the boiler, see diagram 1.1 and 6.1 for position.
Refer also to Section 5 “Domestic Hot Water System”.
Provision is made for the water connections to be connected
from below or from above, passing down either side of the
boiler. Take care that any pipework connected from above will
clear the expansion vessel. Refer to the wall template. If
connecting from above a piping kit 457160 is available and is
recommended. If necessary, temporarily fit the boiler.
Flush out the domestic water and heating system before
connecting the boiler.
Make the connections to the domestic hot water outlet and the
heating system by means of the isolating valves, see diagram
6.1.
While making the connections. Do not subject any of the
isolating valves to heat as you may damage the seals.
Make sure that the drain screw heads on the isolating valves are
accessible.
6.4 Safety Valve Discharge
WARNING. It must not discharge above an entrance or window
or any type of public access area.
A short discharge pipe is supplied loose with the boiler, which
when fitted to the safety valve, will end below the boiler the
position is next to the heating return, see diagram 6.2. (THE
DISCHARGE PIPE MUST BE FITTED BEFORE THE BOILER
IS MOUNTED ON THE WALL).
This must be extended, using not less than 15mm od metal
pipe, to discharge, in a visible position, outside the building,
facing downwards, preferably over a drain. The pipe must have
a continuous fall and be routed to a position so that any
discharge of water, possibly boiling, or steam cannot create any
danger to persons, damage to property or external electrical
components and wiring.
Note. To ease future servicing it is advisable to use a compression
type fitting to extend the discharge pipe.
6 Installation Preparation and Gas / Water Connections
Diagram 6.1
6956
GAS
SERVICE
COCK
HOT
WATER
OUT
COLD
WATER
SUPPLY
IN
HEATING
FLOW
HEATING
RETURN
SLOT (OPEN)
COLD WATER
SUPPLY IN/OUT
SLOT (OPEN)
GAS SERVICE
COCK
SLOT (OPEN)
HEATING
FLOW/ RETURN
SAFETY DISCHARGE
PIPE ROUTING POSITION

Supplied By www.heating spares.co Tel. [phone]
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221679H
TOP STD.
REAR
SIDE
TOP EXTD.
REAR
SIDE
MINIMUM
WALL
THICKNESS
MINIMUM
FLUE
LENGTH
MAXIMUM
FLUE
LENGTH
"Y"
BOILER MOUNTING FACE
TO EXTERNALWALL FACE
"X"
BOILER CASINGTO
EXTERNALWALL FACE
MAXIMUM DISTANCE FROM
126
212
519
-
-
438
75
75
75
75
126
212
840
840
789
-
-
708
570
570
FLUE
PACKS
NOTE :
IF IT IS NECESSARY TO CUT THE DUCTS
TO ACHIEVE THE "FLUE LENGTH" MAKE SURE
THAT THE OVERLAPS ARE AS FOLLOWS :-
THE OVERLAP FOR AIR DUCT = 25mm
THE OVERLAP FOR FLUE DUCT = 50mm
THE MAXIMUM LENGTHS CAN BE INCREASED
BY AN ADDITIONAL 3 METRES WITH THE USE
OF THE 1 METRE EXTENSION KITS.
NOTE :THIS APPLIES TO STANDARD KITS ONLY.
REAR FLUE
SIDE FLUE
15mm
VIEW ’B’
VIEW ’B’
15mm
STD./EXTD.TOP OUTLET FLUE PACK & 1 METRE EXTENSION KIT
SCREW
& TAPE
SCREW
& TAPE
SCREW
& TAPE
SCREW
& TAPE
3 x 1 metre extension kits may be joined together.
FLUE LENGTH
MAX 840mm (extd.)
MAX 570mm (std)
FLUE LENGTH
MAX 840mm (extd.)
MAX 570mm (std)
15mm
SCREW
& TAPE
117mm
36mm
TOP OUTLET FLUE PACK
’X’
’X’plus 132mm = FLUE LENGTH
SIDE FLUE ’X’plus 132mm = FLUE LENGTH REAR FLUE ’Y’plus 50mm = FLUE LENGTH
’Y’
’X’
’Y’plus 50mm = FLUE LENGTH
’Y’
C
L
C
L
Diagram 7.1
7508
7 Flue Preparation
7506
7.1 Flue Position and Length
Determine flue application, length and terminal position before
starting, refer to diagram 7.1.
Note: The Standard Top Outlet Flue Pack and the Extended
Top Outlet Flue Pack contains a flue duct extension piece
complete with "O" rings, this should be discarded.
If you are using a Flue Bend or a Vertical Flue Kit, please follow
the instructions supplied with the kit.
To make a neat finish to the flue outlet a flue collar kit, part No.
443286, with instructions, is available, see diagram 7.2.
Note: If required an optional wall liner kit, part no. 900862, is
available complete with instructions.
7.2 Flue Assembly
Extend the telescopic flue to the required length, making sure
that the minimum overlap is no less than 25mm, and that the flue
terminal projects 15mm minmum beyond wall face, see diagram
7.1.
Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack, see diagram 7.1.
Seal the joint with the tape provided.
If the flue system requires the addition of flue extension kits,
drill, seal and secure them with the self tapping screw and tape
provided.

Supplied By www.heating spares.co Tel. [phone]
15 221679H
Note: Should any one of the flue sections require cutting to
obtain desired flue system length, cut at the end opposite the
expanded end.
If the boiler is not to be fitted for some time cover the hole in the
wall.
7.3 Internal Access Flue
If access to the outside wall is not practical, the flue system can
be installed from inside. Use of the optional wall liner kit is
required.
7.4 Top Outlet Rear Flue Fixing
Fit the self adhesive foam seal provided in the flue pack around
the air duct at the position shown in diagram 7.1.
Make good around the flue outside after installation of the boiler.
Important: If the wall liner kit is used, the self adhesive foam seal
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 7.3 for position of self
adhesive seal.
7.5 Top Outlet Side Flue Fixing
Make good the area around the flue inside and outside after
installation of the boiler.
Important: If the wall liner kit is used, the self adhesive foam seal
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 7.3 for position of self
adhesive seal.
7.6 Flue Positioning
Push the flue assembly into and through the hole such that it is
within the wall, and does not stick out into the room. Do not push
the flue assembly too far into the hole as it has to be pulled back
into the boiler and secured.
7 Flue Preparation
Diagram 7.2
7148
OPTIONAL
FLUE
COLLAR
Diagram 7.3
FOAM SEAL
FOAM SEAL
WALL THICKNESS-
OVER 300mm
15mm
WALL THICKNESS-
UP TO 300mm
Q-35mm
Q
Q
7331
WITH WALL LINER KIT ONLY

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221679H
Diagram 8.1
7232
INNER
CASE
FRONT SECURING
SCREW (4)
Diagram 8.2
7234
ELECTRICAL
CONNECTORS
SECURING
SCREW (2)
REAR
BRACKET
FLUE
COLLECTOR
RED AIR PRESSURE
SWITCH TUBES
8 Mounting the boiler and Flue Fitting
8.1 Boiler Mounting
Remove the inner case front, see diagram 8.1.
To assist with the location of the flue elbow into the fan outlet
remove the fan by removing the securing screws, the electrical
connections by pulling the boots not the wires and air pressure
switch tubes, see diagram 8.2.
Remove the protective caps from the boiler water pipes
Fit the sealing washers (supplied in the fittings pack) to the
boiler water pipes by inseting them into the tubing nuts. (the
nipples on the washers will hold them in position), see diagram
8.4.
Lift the boiler into position on the top mounting brackets, see
diagram 8.3.
8.2 Water and Gas Connections
Locate the boiler water pipes and gas supply pipe, making sure
the washers are retained in the tubing nuts, onto the isolation
valves, fully push the boiler back, see diagram 8.4.
Ensure the bottom boiler bracket is sitting on top of the service
cock bracket, see diagram 8.3.
Fit the flow restrictor into the domestic water inlet, see diagram
8.4.
Secure all tubing nuts finger tight, plus 3/4turn maximum.
Connect the gas pipe to the isolation valve ensuring that the
sealing washer (supplied fitted) is in position.
8.3 Boiler Securing
Secure the boiler with the two boiler securing screws supplied
loose, to the service cock bracket, see diagram 8.3.
An anti theft kit is available, Kit No. 457110
8.4 Flue Fixing to the Boiler
Make sure that the ductings do not slope down towards the
boiler.
Position the restrictor plate supplied in the loose items pack,
between the flue elbow and boiler , (gasket facing upwards). Fit
the flue elbow to the restrictor plate and top of the boiler using
the four screws supplied, see diagram 8.5.
Tighten the four screws of the flue elbow evenly to ensure a
good seal at the gasket.
Make the wall good internally and externally around the air duct,
also making it weatherproof on the outer wall a flue collar kit is
available Pt. No. 443286.
Refit fan retained by the rear bracket and two securing screws.
Refit the inner case front.
FAN
WHITE AIR
PRESSURE
SWITCH
TUBES

Supplied By www.heating spares.co Tel. [phone]
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7075
TOP MOUNTING
BRACKET
BOILER
RETAINING LUG
Diagram 8.5
RESTRICTOR/
GASKET
7233
FLUE ELBOW
(REAR FLUE
SHOWN)
SECURING
SCREW (4)
PRODUCTS
PROBE
8 Mounting the Boiler and Flue Fitting
Diagram 8.3
SECURING
SCREW (2)
SERVICE COCK
BRACKET
BOILER
SECURING LUG
Note: The lug must
be positioned on top
of the service cock
bracket
8083
Diagram 8.4
BOILER WATER PIPES
SERVICE
COCKS (4)
GAS SUPPLY
PIPE
SEALING
WASHER (4)
(INSERT INTO
TUBING NUT)
FLOW
RESTRICTOR
(DOMESTIC WATER INLET)
TUBING
NUT

Supplied By www.heating spares.co Tel. [phone]
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R2
R1
N
L
9 Electrical Connections
Diagram 9.2
7024
CABLE
CLAMP
MAINS
CABLE
SCREW (2)
BUSH
CONNECTION
BLOCK
9.1 Supply Cable Connection
CAUTION: To prevent an induced current from switching the
central heating on, when not required, it is important that the
heating system control cables are separated from the other
mains supply cables.
Open the controls cover door. Remove the two screws securing
the controls facia, see diagram 9.1.
Hinge the control fascia open.
The boiler requires a permanent mains supply through an
external isolator which must also isolate any heating system
controls, see diagram 9.2.
Any heating system controls must not interrupt the permanent
mains supply to the boiler.
Using PVC cable of a suitable length and rating as stated in
Section 1.8 “Electrical Supply”, route the mains supply cable
and connect to the appropriate terminals of the connector block,
restrain with the cable clamp supplied, see diagram 9.2.
Standard colours are, Brown - Live, Blue - Neutral, Green and
Yellow - Earth.
Make the earth cable of a greater length so that if the cable is
strained the earth would be the last to become disconnected.
CAUTION: It is ESSENTIAL to make sure that the polarity is
correct.
9.2 Heating System Controls
All external controls and wiring are required to provide a
minimum of reinforced insulation at 250Vrms between the parts
of those devices operating at mains hazardous voltage and the
user accessible parts af those devices.
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostatic radiator valves may be installed in addition to the
room thermostat.
Note: For further information, see The Building Regulations
1991 - Conservation of fuel and power, 1995 edition - Appendix
G, table 4b.
If electrical controls are not to be used to regulate the heating
system, do not remove the red link cable.
When any form of electrical control is being used to regulate the
heating system, remove the red link cable and connect heating
system controls in series.
9.3 Clock/timer Kit (if applicable)
Fit the clock/timer kit following the appropriate sections of the
instructions supplied with it..
9.4 Frost Thermostat
If the installation requires protection by a “frost thermostat”,
connect a single pole type, to the appropriate terminals of the
connector, see diagram 9.3.
Electrical Checks
Keep all cables away from hot surfaces.
Carry out preliminary electrical system checks as below:
1. Test insulation resistance to earth of mains cables.
2. Test earth continuity and short circuit of all cables
3. Test the polarity of the mains.
Refit the controls fascia.
RED
LINK
Diagram 9.1
7189
CONTROLS COVER
SECURING
SCREW (2)
CONTROLS
FASCIA

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9 Electrical Connections
Diagram 9.3
7100
JUNCTION
BOX
3 AMP
FUSE
LN
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~50Hz
ROOM STAT.
230V~50Hz
FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 WAY TERMINAL BLOCK
230V~50Hz
POTENTIAL
FROST STAT.
230V~50Hz
POTENTIAL
ROOM STAT.
(L) (N) (R1) (R2)
JUNCTION
BOX
3 AMP
FUSE
LN
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~50Hz
ROOM STAT. USED AS LINK
230V~50Hz
FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 WAY TERMINAL BLOCK
MAINS
POTENTIAL
FROST STAT.
MAINS
POTENTIAL
ROOM STAT.
(L) (N) (R1) (R2)
JUNCTION
BOX
3 AMP
FUSE
LN
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~50Hz
FROST STAT. NO ROOM STAT.
TO BOILER
RED
LINK
5 WAY TERMINAL BLOCK
MAINS
POTENTIAL
FROST STAT.
(L) (N) (R1) (R2)
3 AMP
FUSE
LN
230V~50Hz
PERMANENT MAINS
SUPPLY
POTENTIAL
FREE ROOM STAT. NO FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 WAY TERMINAL BLOCK
POTENTIAL FREE
ROOM STAT.
(L) (N) (R1) (R2)
DOUBLE
POLE
ISOLATOR
JUNCTION
BOX
3 AMP
FUSE
LN
230V~50Hz
PERMANENT MAINS
SUPPLY
230V~50Hz ROOM STAT. NO FROST STAT.
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING
SYSTEM CONTROLS
5 WAY TERMINAL BLOCK
MAINS POTENTIAL
ROOM STAT.
(L) (N) (R1) (R2)
5 WAY TERMINAL BLOCK
TO BOILER
RED LINK.
REMOVE WHEN
CONNECTING ANY
HEATING SYSTEM
CONTROLS
TIME
CONTROL
CLOCK
SWITCH
CONTACTS
(L) (N) (R1) (R2)
JUNCTION
BOX
3 AMP
FUSE
ROOM
THERMOSTAT
FROST
THERMOSTAT
LNE
230V~50Hz
PERMANENT
MAINS SUPPLY
ELECTRICITY SUPPLY CONNECTIONS
EXTERNAL CLOCK INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
INTEGRAL CLOCK
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
DOUBLE
POLE
ISOLATOR
E
E
E
E
E

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7034
Diagram 10.1
BURNER
PRESSURE TEST
POINT
GAS CONTROL
VALVE
WARNING 230V 50Hz
ELECTRICAL
CONNECTIONS
Please ensure the “Benchmark”logbook is completed and left
with the user.
10.1 Filling Domestic Water Circuit
Check that the boiler is isolated from the electrical supply, at the
external isolator.
Fully open the domestic water supply stop cock or valve in the
supply to the boiler.
Open the domestic water isolation valve, lever in line with the
valve body, see diagram 6.1.
Open all hot water draw-off taps and close them when water
flows. Check for water soundness of the whole domestic water
system and boiler.
10.2 Filling the Heating System
Open the two central heating isolating valves, levers in line with
the valve body, see diagram 6.1.
Flush, fill and vent the system refer to Section 4.8 “Filling
Sealed Systems”.
WARNING. SEVERAL COMPONENTS OPERATE ON MAINS
VOLTAGE AND WITH THE OUTER CASE REMOVED, LIVE
COMPONENTS BECOME EXPOSED.
To assist in filling and venting, the pump may be operated:
Connect the electrical supply, refer to diagram 4 "Instructions
for Use", set button “J”to “winter”, “F”will illuminate, set any
remote heating systems controls, time switch and/or room
thermostat to call for heat.
Note. If the clock/timer kit is to be fitted, refer to the setting
instructions in the Instructions for Use.
Make sure that the automatic air vent is operating correctly.
Take care not to splash any of the electrical components.
Open the controls cover.
Refer to diagram 4 "Instructions for Use". Operate button “J”
between “H”summer and “F”winter to ensure that water flows
through all parts of the boiler and air is not trapped in the boiler
internal bypass.
Pressurise the system until the pressure is 1.5bar (21.5lbf/in2).
Check the heating system and boiler for water soundness.
Check the operation of the safety valve by turning the safety
valve knob in the direction of the arrow.
Lower the pressure to the initial cold fill design pressure, refer
to Table 1. Position the set pointer on the boiler pressure gauge
at this pressure also.
Refit inner case front.
10.3 Preparation for Lighting
Turn on the gas service cock, slot in line with the length of the
cock.
Test for soundness and purge air from the gas supply.
Switch power 'ON' at the mains electrical supply at the external
isolator and switch at the boiler.
Light the pilot refer to relevant parts of "Light the boiler"
(Instructions for Use).
Loosen the burner pressure test point screw and connect a
suitable pressure gauge, see diagram 10.1.
10 Commissioning
10.4 Burner Pressure - Hot Water
Connect the electrical supply it will default to winter, select
summer, the pump will operate for about 30 seconds then the
pump will stop.
Fully open the largest hot water draw off tap whereby the main
burner will light, the flames gradually increasing to the maximum.
Check the soundness of the boiler gas joints, with the main
burner on, using a leak detection fluid. Take care not to splash
any of the electrical components.
To achieve this flow rate a water pressure of at least 0.8bar is
required during commissioning, although subsequently the
appliance will work at a minimum pressure of 0.5bar.
This flow rate should prevent any modulation of the gas pressure.
The burner pressure is factory preset and no adjustment should
be required.
Check the burner pressure is within +/-0.35mbar (+/-0.14in wg).
of 13.0mbar (5.22in wg). If this is incorrect, the burner pressure
may be adjusted to the correct setting by turning the hot water
gas pressure adjuster (potentiometer), located on the control
board to gain access remove the two screws securing the
controls facia, see diagram 9.1.
Hinge the control facia forward.
Remove the plastic plugs. Using the burner adjusting tool
supplied. (Clockwise to increase), see diagram 10.2. Turn the
adjuster slowly, always making adjustment by reducing below
the required pressure then increasing up to the required setting.
Close the hot water draw off.
If the maximum pressure cannot be obtained, check that the gas
supply is of adequate size, refer to Section 1.7.
10.5 Gas Rate Modulation
The minimum gas rate is factory preset and no adjustment
should be required.
ALWAYS CHECK HOT WATER BURNER PRESSURE FIRST
- REFER TO SECTION 10.4.
To check the minimum gas rate, first make sure that the boiler
is isolated from the electrical supply at the external isolator